Sartor, Joe Don (Longmont, CO, US)
Harvilla, Dennis J. (Lafayette, CO, US)

10/473618

09/12/2006

04/05/2002

Download PDF 7103947       PDF help

Click for automatic bibliography generation

Sherwood Services AG (Schaffhausen, CH)

29/11

29/460, 29/527.100

B21K13/02; B21D53/40

606/51, 29/527.1, 29/460, 606/48, 606/50, 29/11, 29/527.2

4416276	Adaptive, return electrode monitoring system	November, 1983	Newton et al.
4452246	Surgical instrument	June, 1984	Bader et al.
4492231	Non-sticking electrocautery system and forceps	January, 1985	Auth
4552143	Removable switch electrocautery instruments	November, 1985	Lottick
4574804	Optic nerve clamp	March, 1986	Kurwa
4597379	Method of coagulating muscle tissue	July, 1986	Kihn et al.
4600007	Parametrium cutting forceps	July, 1986	Lahodny et al.
4657016	Electrosurgical handpiece for blades, needles and forceps	April, 1987	Garito et al.
4662372	Disposable surgical instrument and method of forming	May, 1987	Sharkany et al.
4671274	Bipolar electrosurgical instrument	June, 1987	Sorochenko
4685459	Device for bipolar high-frequency coagulation of biological tissue	August, 1987	Xoch et al.
4715122	Plastic handle scissors	December, 1987	Linden	30/254
D295893	Disposable surgical clamp	May, 1988	Sharkany et al.
D295894	Disposable surgical scissors	May, 1988	Sharkany et al.
4763669	Surgical instrument with adjustable angle of operation	August, 1988	Jaeger
4827929	Angulated surgical instrument	May, 1989	Hodge
4887612	Endoscopic biopsy forceps	December, 1989	Esser et al.
4938761	Bipolar electrosurgical forceps	July, 1990	Ensslin
4985030	Bipolar coagulation instrument	January, 1991	Melzer et al.
5007908	Electrosurgical instrument having needle cutting electrode and spot-coag electrode	April, 1991	Rydell
5026370	Electrocautery instrument	June, 1991	Lottick
5099840	Diathermy unit	March, 1992	Goble et al.
5116332	Electrocautery hemostat	May, 1992	Lottick
5147357	Medical instrument	September, 1992	Rose et al.
5151102	Blood vessel coagulation/stanching device	September, 1992	Xamiyama et al.
5176695	Surgical cutting means	January, 1993	Dulebohn
5190541	Surgical instrument and method	March, 1993	Abele et al.
5197964	Bipolar instrument utilizing one stationary electrode and one movable electrode	March, 1993	Parins
5215101	Sharply angled kelly (Jacobs's) clamp	June, 1993	Jacobs et al.
5217457	Enhanced electrosurgical apparatus	June, 1993	Delahuerga et al.
5217458	Bipolar biopsy device utilizing a rotatable, single-hinged moving element	June, 1993	Parins
5244462	Electrosurgical apparatus	September, 1993	Delahuerga et al.
5250047	Bipolar laparoscopic instrument with replaceable electrode tip assembly	October, 1993	Rydell
5258006	Bipolar electrosurgical forceps	November, 1993	Rydell et al.
5261918	Sheathed surgical instrument and applicator kit	November, 1993	Phillips et al.
5275615	Medical instrument having gripping jaws	January, 1994	Rose
5277201	Endometrial ablation apparatus and method	January, 1994	Stern
5282799	Bipolar electrosurgical scalpel with paired loop electrodes	February, 1994	Rydell
5290286	Bipolar instrument utilizing one stationary electrode and one movable electrode	March, 1994	Parins
5304203	Tissue extracting forceps for laparoscopic surgery	April, 1994	El-Mallawany et al.
5308357	Handle mechanism for manual instruments	May, 1994	Lichtman
5318589	Surgical instrument for endoscopic surgery	June, 1994	Lichtman
5324289	Hemostatic bi-polar electrosurgical cutting apparatus and methods of use	June, 1994	Eggers
5330471	Bi-polar electrosurgical endoscopic instruments and methods of use	July, 1994	Eggers
5334183	Endoscopic electrosurgical apparatus	August, 1994	Wuchinich
5334215	Pincers having disposable end members	August, 1994	Chen
5336221	Method and apparatus for applying thermal energy to tissue using a clamp	August, 1994	Anderson
5342359	Bipolar coagulation device	August, 1994	Rydell
5342381	Combination bipolar scissors and forceps instrument	August, 1994	Tidemand
5342393	Method and device for vascular repair	August, 1994	Stack
5352222	Surgical scissors with bipolar coagulation feature	October, 1994	Rydell
5354271	Vascular sheath	October, 1994	Voda
5356408	Bipolar electrosurgical scissors having nonlinear blades	October, 1994	Rydell
5366477	Actuating forces transmission link and assembly for use in surgical instruments	November, 1994	LeMarie, III et al.
5383897	Method and apparatus for closing blood vessel punctures	January, 1995	Wholey
5389098	Surgical device for stapling and/or fastening body tissues	February, 1995	Tsuruta et al.
5389104	Arthroscopic surgical instruments	February, 1995	Hahnen et al.
5391166	Bi-polar electrosurgical endoscopic instruments having a detachable working end	February, 1995	Eggers
5391183	Device and method sealing puncture wounds	February, 1995	Janzen et al.
5403312	Electrosurgical hemostatic device	April, 1995	Yates et al.
5411519	Surgical apparatus having hinged jaw structure	May, 1995	Tovey et al.
5411520	Hemostatic vessel puncture closure system utilizing a plug located within the puncture tract spaced from the vessel, and method of use	May, 1995	Nash et al.
5413571	Device for sealing hemostatic incisions	May, 1995	Katsaros et al.
5415657	Percutaneous vascular sealing method	May, 1995	Taymor-Luria
5423810	Cauterising apparatus	June, 1995	Goble et al.
5425739	Anastomosis stent and stent selection system	June, 1995	Jessen
5429616	Occludable catheter	July, 1995	Schaffer
5431674	Compound motion cutting device	July, 1995	Basile et al.
5437292	Method for sealing blood vessel puncture sites	August, 1995	Kipshidze et al.
5438302	Electrosurgical radiofrequency generator having regulated voltage across switching device	August, 1995	Goble
5441517	Hemostatic puncture closure system and method of use	August, 1995	Kensey et al.
5443463	Coagulating forceps	August, 1995	Stern et al.
5443464	External fixator apparatus	August, 1995	Russell et al.
5443480	Sharply angled kelly (Jacobs) clamp	August, 1995	Jacobs et al.
5445638	Bipolar coagulation and cutting forceps	August, 1995	Rydell et al.
5445658	Gasification apparatus for a finely divided combustible material	August, 1995	Durrfeld et al.
5451224	Apparatus for radio frequency bipolar electrosurgery	September, 1995	Goble et al.
5456140	Method for producing a pivoted tool having a self-compensating unitary pivot member	October, 1995	Linden et al.	76/106.5
5456684	Multifunctional minimally invasive surgical instrument	October, 1995	Schmidt et al.
5458598	Cutting and coagulating forceps	October, 1995	Feinberg et al.
5460629	Electrosurgical device and method	October, 1995	Shlain et al.
5461765	Method of making a pivoted tool having integral pivot member	October, 1995	Linden et al.	29/434
5462546	Bipolar electrosurgical forceps	October, 1995	Rydell
5472443	Electrosurgical apparatus employing constant voltage and methods of use	December, 1995	Cordis et al.
5478351	Endoscopic surgical tool with handle and detachable tool assembly	December, 1995	Meade et al.
5480409	Laparoscopic surgical instrument	January, 1996	Riza
5484436	Bi-polar electrosurgical instruments and methods of making	January, 1996	Eggers et al.
5496317	Laparoscopic surgical instrument	March, 1996	Goble et al.
5496347	Surgical instrument	March, 1996	Hashiguchi et al.
5499997	Endoscopic tenaculum surgical instrument	March, 1996	Sharpe et al.
5509922	Endoscopic surgical instrument	April, 1996	Aranyi et al.
5514134	Bipolar electrosurgical scissors	May, 1996	Rydell et al.
5527313	Bipolar surgical instruments	June, 1996	Scott et al.
5531744	Alternative current pathways for bipolar surgical cutting tool	July, 1996	Nardella et al.
5536251	Thoracoscopic devices and methods for arresting the heart	July, 1996	Evard et al.
5540684	Method and apparatus for electrosurgically treating tissue	July, 1996	Hassler, Jr.
5540685	Bipolar electrical scissors with metal cutting edges and shearing surfaces	July, 1996	Parins et al.
5540715	Device for sealing hemostatic incisions	July, 1996	Katsaros et al.
5558672	Thin layer ablation apparatus	September, 1996	Edwards et al.
5562699	Forceps	October, 1996	Heimberger et al.
5569241	Thin layer ablation apparatus	October, 1996	Edwards
5569243	Double acting endoscopic scissors with bipolar cautery capability	October, 1996	Kortenbach et al.
5571100	Electrosurgical apparatus	November, 1996	Goble et al.
5573424	Apparatus for interfacing a bipolar electrosurgical instrument to a monopolar generator	November, 1996	Poppe
5573534	Bipolar electrosurgical instruments	November, 1996	Stone
5573535	Bipolar surgical instrument for coagulation and cutting	November, 1996	Viklund
5582611	Surgical device for stapling and/or fastening body tissues	December, 1996	Tsuruta et al.
5585896	Image forming apparatus with a contact member contacting an image carrier	December, 1996	Yamazaki et al.
5590570	Actuating forces transmission link and assembly for use in surgical instruments	January, 1997	LeMaire, III et al.
5591202	Endoscopic instruments having low friction sheath	January, 1997	Slater et al.	606/205
5603711	Endoscopic bipolar biopsy forceps	February, 1997	Parins et al.
5603723	Surgical instrument configured to be disassembled for cleaning	February, 1997	Aranyi et al.
5626578	RF valvulotome	May, 1997	Tihon
5626609	Endoscopic surgical instrument	May, 1997	Zvenyatsky et al.
5630833	Device for sealing hemostatic incisions	May, 1997	Katsaros et al.
5637110	Electrocautery surgical tool with relatively pivoted tissue engaging jaws	June, 1997	Pennybacker et al.
5643294	Surgical apparatus having an increased range of operability	July, 1997	Tovey et al.
5647869	Electrosurgical apparatus	July, 1997	Goble et al.
5647871	Electrosurgery with cooled electrodes	July, 1997	Levine et al.
5649959	Assembly for sealing a puncture in a vessel	July, 1997	Hannam et al.
5658281	Bipolar electrosurgical scissors and method of manufacture	August, 1997	Heard
5662667	Surgical clamping mechanism	September, 1997	Knodel
5667526	Tissue retaining clamp	September, 1997	Levin
5674220	Bipolar electrosurgical clamping device	October, 1997	Fox et al.
5681282	Methods and apparatus for ablation of luminal tissues	October, 1997	Eggers et al.
5693051	Electrosurgical hemostatic device with adaptive electrodes	December, 1997	Schulze et al.
5695522	Actuating forces transmission link and assembly for use in surgical instruments	December, 1997	LeMaire, III et al.
5700261	Bipolar Scissors	December, 1997	Brinkerhoff
5702390	Bioplar cutting and coagulation instrument	December, 1997	Austin et al.
5707369	Temperature feedback monitor for hemostatic surgical instrument	January, 1998	Vaitekunas et al.
5709680	Electrosurgical hemostatic device	January, 1998	Yates et al.
5716366	Hemostatic surgical cutting or stapling instrument	February, 1998	Yates
5727428	Actuating forces transmission link and assembly for use in surgical instruments	March, 1998	LeMaire, III et al.
5735848	Electrosurgical stapling device	April, 1998	Yates et al.
5743906	Endoscopic bipolar biopsy forceps	April, 1998	Parins et al.
5755717	Electrosurgical clamping device with improved coagulation feedback	May, 1998	Yates et al.
5766130	Vascular testing method	June, 1998	Selmonosky
5766166	Bipolar Electrosurgical scissors	June, 1998	Hooven
5766170	Electrosurgical endoscopic instruments and methods of use	June, 1998	Eggers
5769849	Bi-polar electrosurgical endoscopic instruments	June, 1998	Eggers
5776128	Hemostatic bi-polar electrosurgical cutting apparatus	July, 1998	Eggers
5776130	Vascular tissue sealing pressure control	July, 1998	Buysse et al.
5779701	Bipolar endoscopic surgical scissor blades and instrument incorporating the same	July, 1998	McBrayer et al.
5792137	Coagulating microsystem	August, 1998	Carr et al.
5792177	Forceps	August, 1998	Kaseda
5797938	Self protecting knife for curved jaw surgical instruments	August, 1998	Paraschac et al.
5797958	Endoscopic grasping instrument with scissors	August, 1998	Yoon
5800449	Knife shield for surgical instruments	September, 1998	Wales
5810808	Hemostatic bi-polar electrosurgical cutting apparatus and methods of use	September, 1998	Eggers
5810811	Electrosurgical hemostatic device	September, 1998	Yates et al.
5810877	Endoscopic microsurgical instruments and methods	September, 1998	Roth et al.
5814043	Bipolar electrosurgical device	September, 1998	Shapeton
5820630	Medical forceps jaw assembly	October, 1998	Lind
5827271	Energy delivery system for vessel sealing	October, 1998	Buysse et al.
5827279	Knife coupler mechanism for an endoscopic instrument	October, 1998	Hughett et al.
5827281	Insulated surgical scissors	October, 1998	Levin
5833690	Electrosurgical device and method	November, 1998	Yates et al.
5843080	Bipolar instrument with multi-coated electrodes	December, 1998	Fleenor et al.
5849022	Medical instrument for use in combination with endoscopes	December, 1998	Sakashita et al.
5853412	Bipolar surgical grasping instrument	December, 1998	Mayenberger
5876401	Electrosurgical hemostatic device with adaptive electrodes	March, 1999	Schulze et al.
5891141	Bipolar electrosurgical instrument for cutting and sealing tubular tissue structures	April, 1999	Rydell
5891142	Electrosurgical forceps	April, 1999	Eggers et al.
5893863	Surgical instrument with jaws and movable internal hook member for use thereof	April, 1999	Yoon
5893875	Surgical instrument with replaceable jaw assembly	April, 1999	O'Connor et al.
5893877	Surgical instrument with offset handle	April, 1999	Gampp, Jr. et al.
5902301	Cutting/coagulating forceps with interleaved electrodes	May, 1999	Olig
5906630	Eccentric surgical forceps	May, 1999	Anderhub et al.
5908420	Surgical scissors with bipolar distal electrodes	June, 1999	Parins et al.
5913874	Cartridge for a surgical instrument	June, 1999	Berns et al.
5921984	Bipolar electrosurgical instrument with coagulation feature	July, 1999	Sutcu et al.
5935126	Surgical instrument with jaws having electrical contacts	August, 1999	Riza
5944718	Electrosurgical instrument end effector	August, 1999	Austin et al.
5951549	Bipolar electrosurgical scissors	September, 1999	Richardson et al.
5954720	Bipolar electrosurgical end effectors	September, 1999	Wilson et al.
5976132	Bipolar surgical shears	November, 1999	Morris
5989277	Surgical instrument with offset jaw actuator	November, 1999	LeMaire, III et al.
6004335	Ultrasonic hemostatic and cutting instrument	December, 1999	Vaitekunas et al.
6010516	Bipolar coaptation clamps	January, 2000	Hulka
6024741	Surgical tissue treating device with locking mechanism	February, 2000	Willaimson et al.
6024744	Combined bipolar scissor and grasper	February, 2000	Kese et al.
6033399	Electrosurgical generator with adaptive power control	March, 2000	Gines
6039733	Method of vascular tissue sealing pressure control	March, 2000	Buysse et al.
6041679	Endoscopic end effectors constructed from a combination of conductive and non-conductive materials and useful for selective endoscopic cautery	March, 2000	Slater et al.	76/104.1
6050996	Bipolar electrosurgical instrument with replaceable electrodes	April, 2000	Schmaltz et al.
6053914	Pivot screw for bipolar surgical instruments	April, 2000	Eggers et al.
6053933	Gripping unit for application in minimally invasive surgery	April, 2000	Balazs et al.
D424694	Forceps	May, 2000	Tetzlaff et al.
D425201	Disposable electrode assembly	May, 2000	Tetzlaff et al.
6060695	Electrically heated scissors with cutting blade of each limb comprising electric heating layer or insert	May, 2000	Harle et al.	219/229
6083223	Methods and apparatus for welding blood vessels	July, 2000	Baker
6086586	Bipolar tissue grasping apparatus and tissue welding method	July, 2000	Hooven
6090107	Resposable electrosurgical instrument	July, 2000	Borgmeier et al.
6096031	High repetition rate erbium:YAG laser for tissue ablation	August, 2000	Mitchell et al.
6096037	Tissue sealing electrosurgery device and methods of sealing tissue	August, 2000	Mulier et al.
6099550	Surgical instrument having jaws and an operating channel and method for use thereof	August, 2000	Yoon
6102909	Scissorlike electrosurgical cutting instrument	August, 2000	Chen et al.
6110171	Electrosurgical cutting and coagulating instrument for open surgery	August, 2000	Rydell
6113596	Combination monopolar-bipolar electrosurgical instrument system, instrument and cable	September, 2000	Hooven et al.
6113598	Radiofrequency medical instrument and methods for vessel welding	September, 2000	Baker
6117158	Ratchet release mechanism for hand held instruments	September, 2000	Measamer et al.
H001904	Electrosurgical hemostatic method and device	October, 2000	Yates et al.
6126658	Radiofrequency medical instrument and methods for vessel welding	October, 2000	Baker
6152923	Multi-contact forceps and method of sealing, coagulating, cauterizing and/or cutting vessels and tissue	November, 2000	Ryan
6174309	Seal & cut electrosurgical instrument	January, 2001	Wrublewski et al.
6179834	Vascular tissue sealing pressure control and method	January, 2001	Buysse et al.
6179837	Bipolar electrosurgical scissors	January, 2001	Hooven
6183467	Package for removable device tips	February, 2001	Shapeton et al.
6187003	Bipolar electrosurgical instrument for sealing vessels	February, 2001	Buysse et al.
6190386	Electrosurgical forceps with needle electrodes	February, 2001	Rydell
6193718	Endoscopic electrocautery instrument	February, 2001	Kortenbach et al.
6206876	Electrosurgery with cooled electrodes	March, 2001	Levine et al.
6206877	Combined bipolar scissor and grasper and method of forming thereof	March, 2001	Kese et al.
6224593	Tissue sealing using microwaves	May, 2001	Ryan et al.
6228080	Electrosurgical generator with adaptive power control	May, 2001	Gines
6228083	Laparoscopic bipolar electrosurgical instrument	May, 2001	Lands et al.
6267761	Apparatus and method for sealing and cutting tissue	July, 2001	Ryan
6270497	High-frequency treatment apparatus having control mechanism for incising tissue after completion of coagulation by high-frequency treatment tool	August, 2001	Sekino et al.
6270508	End effector and instrument for endoscopic and general surgery needle control	August, 2001	Klieman et al.
6273887	High-frequency treatment tool	August, 2001	Yamauchi et al.
6277117	Open vessel sealing forceps with disposable electrodes	August, 2001	Tetzlaff et al.
6280458	Surgical grasping and holding forceps	August, 2001	Boche et al.
6283961	Apparatus for electrosurgical spine surgery	September, 2001	Underwood et al.
D449886	Forceps with disposable electrode	October, 2001	Tetzlaff et al.
6312430	Bipolar electrosurgical end effectors	November, 2001	Wilson et al.	606/50
6322561	Pivot screw for bipolar surgical instruments	November, 2001	Eggers et al.
6334860	Bipolar medical instrument	January, 2002	Dorn
6334861	Biopolar instrument for vessel sealing	January, 2002	Chandler et al.
6350264	Bipolar electrosurgical scissors	February, 2002	Hooven
6352536	Bipolar electrosurgical instrument for sealing vessels	March, 2002	Buysse et al.
D457958	Vessel sealer and divider	May, 2002	Dycus et al.
D457959	Vessel sealer	May, 2002	Tetzlaff et al.
6398779	Vessel sealing system	June, 2002	Buysse et al.
6402747	Handswitch cord and circuit	June, 2002	Lindemann et al.
6409728	Rotatable bipolar forceps	June, 2002	Ehr et al.
H002037	Electrosurgical hemostatic device including an anvil	July, 2002	Yates et al.
6419675	Electrosurgical coagulating and cutting instrument	July, 2002	Gallo, Sr.
6425896	Endoscopically useable instrument for coagulation by means of high frequency and for the serving of coagulated tissue areas	July, 2002	Baltschun et al.
6443970	Surgical instrument with a dissecting tip	September, 2002	Schulze et al.
6451018	Laparoscopic bipolar electrosurgical instrument	September, 2002	Lands et al.
6458128	Electrosurgical instrument with a longitudinal element for conducting RF energy and moving a cutting element	October, 2002	Schulze
6458130	Endoscopic bipolar electrosurgical forceps	October, 2002	Frazier et al.
6464704	Bipolar electrosurgical instrument with replaceable electrodes	October, 2002	Schmaltz et al.
6503248	Cooled, non-sticking electrosurgical devices	January, 2003	Levine
6506189	Cool-tip electrode thermosurgery system	January, 2003	Rittman, III et al.
6511480	Open vessel sealing forceps with disposable electrodes	January, 2003	Tetzlaff et al.
6514251	Cooled-wet electrode	February, 2003	Ni et al.
6544264	Electrosurgery with cooled electrodes	April, 2003	Levine et al.
6569162	Passively self-cooled electrode design for ablation catheters	May, 2003	He
6585735	Endoscopic bipolar electrosurgical forceps	July, 2003	Lands et al.
6620161	Electrosurgical instrument with an operational sequencing element	September, 2003	Schulze et al.
6682528	Endoscopic bipolar electrosurgical forceps	January, 2004	Frazier et al.
6685724	Laparoscopic surgical instrument and method	February, 2004	Haluck
6733498	System and method for control of tissue welding	May, 2004	Paton et al.
6743229	Bipolar electrosurgical instrument for sealing vessels	June, 2004	Buysse et al.
6743230	Bipolar grasping instrument	June, 2004	Lutze et al.	606/51
D496997	Vessel sealer and divider	October, 2004	Dycus et al.
D499181	Handle for a vessel sealer and divider	November, 2004	Dycus et al.
6926716	Electrosurgical instrument	August, 2005	Baker et al.
6929644	Electrosurgical jaw structure for controlled energy delivery	August, 2005	Truckai et al.
20020107517	Electrosurgical instrument for coagulation and cutting	August, 2002	Witt et al.
20020188294	Vessel sealer and divider	December, 2002	Couture et al.
20030018331	Vessel sealer and divider	January, 2003	Dycus et al.
20030069571	Electrothermal instrument for sealing and joining or cutting tissue	April, 2003	Treat et al.
20030078578	Electrosurgical instrument and method of use	April, 2003	Truckai et al.
20030139741	Surgical instrument	July, 2003	Goble et al.
20030139742	Feedback light apparatus and method for use with an electrosurgical instrument	July, 2003	Wampler et al.
20030158549	Apparatus for securing an electrophysiology probe to a clamp	August, 2003	Swanson
20030199869	Vessel sealing instrument	October, 2003	Johnson et al.
20040147925	Bipolar electrosurgical instrument for sealing vessels	July, 2004	Buysse et al.
20040225288	Bipolar electrosurgical instrument for sealing vessels	November, 2004	Buysse et al.
20040236325	Vesel sealing forceps with disposable electrodes	November, 2004	Tetzlaff et al.
20040243125	Vessel sealer and divider	December, 2004	Dycus et al.
20040249371	Vessel sealer and divider	December, 2004	Dycus et al.
20040249374	Vessel sealing instrument	December, 2004	Tetzlaff et al.
20040250419	Method of manufacturing jaw assembly for vessel sealer and divider	December, 2004	Sremcich et al.
20040254573	Vessel sealer and divider for use with small trocars and cannulas	December, 2004	Dycus et al.
20050004568	Electrosurgical instrument reducing thermal spread	January, 2005	Lawes et al.
20050004570	Electrosurgical instrument which reduces thermal damage to adjacent tissue	January, 2005	Chapman et al.
20050021025	Electrosurgical instruments which reduces collateral damage to adjacent tissue	January, 2005	Buysse et al.
20050021026	Method of fusing biomaterials with radiofrequency energy	January, 2005	Baily
20050021027	Tissue sealer with non-conductive variable stop members and method of sealing tissue	January, 2005	Shields et al.
20050101951	Vessel sealing system	May, 2005	Wham et al.
20050113818	Connector systems for electrosurgical generator	May, 2005	Sartor et al.

CA2104423	February, 1994
DE2415263	October, 1975
DE29616210	January, 1997
DE19608716	April, 1997
DE19751108	May, 1999
DE19828976	February, 2000
DE20001204	March, 2000
EP0364216	April, 1990			Screening and monitoring instrument.
EP0518230	December, 1992			Bi-polar electrosurgical endoscopic instruments and methods for use.
EP0541930	May, 1993			Transmission link for use in surgical instruments.
EP0572131	December, 1993			Surgical scissors with bipolar coagulation feature.
EP0584787	March, 1994			Endoscopic surgical instrument.
EP0623316	November, 1994			Laparoscopic surgical instrument.
EP0624348	November, 1994			Bipolar electrosurgical instruments.
EP0650701	May, 1995			Electrosurgical apparatus for laporoscopy and similar interventions.
EP0694290	March, 1996			Electrosurgical apparatus
EP0717966	June, 1996			Electrosurgical bipolar scissors
EP0754437	March, 1997			An electrosurgical generator and system
EP0853922	July, 1998			Bipolar electrosurgical scissors
EP0887046	January, 1999			Laparoscopic surgical instrument
EP0923907	June, 1999			An electrosurgical instrument
EP1034747	September, 2000			Electrosurgery system and instrument
EP1034748	September, 2000			UHF electrosurgery system
EP1025807	October, 2000			An electrosurgical instrument
EP1034746	October, 2000			Electrosurgical apparatus
EP1050278	November, 2000			An electrosurgical instrument
EP1053719	November, 2000			Electrosurgery system and instrument
EP1053720	November, 2000			Electrosurgery system and method
EP1055399	November, 2000			An electrosurgical generator and system
EP1055400	November, 2000			An electrosurgical instrument
EP1080694	March, 2001			An electrosurgical generator.
EP1082944	March, 2001			An electrosurgical generator and system
EP1159926	December, 2001			Scissor- or forceps-like surgical instrument
GB2214430	June, 1989
JP0501068	September, 1984
JP0502328	March, 1992
JP0540112	February, 1993
JP06343644	December, 1994
JP07265326	October, 1995
JP07265328	October, 1995
JP08056955	March, 1996
JP08252263	October, 1996
JP09010223	January, 1997
JP11244298	September, 1999			ELECTRIC SURGICAL INSTRUMENT
JP2000342599	December, 2000
JP2000350732	December, 2000
JP2000034259	December, 2000			POLYAMINE
JP2001008944	January, 2001			ELECTRIC SURGICAL SIGNAL GENERATOR AND ELECTRIC SURGICAL SYSTEM
JP2001029356	February, 2001
JP2001128990	May, 2001
RU401367	November, 1974
SU401367	November, 1974
WO/1992/006642	April, 1992			SURGICAL INSTRUMENT AND METHOD
WO/1994/008524	April, 1994			ELECTROSURGICAL INSTRUMENTS HAVING A DETACHABLE WORKING END
WO/1995/002369	January, 1995			AN ELECTROSURGICAL GENERATOR
WO/1995/007662	March, 1995			ENDOSCOPIC SURGICAL INSTRUMENT WITH GUIDED JAWS AND RATCHET CONTROL
WO/1996/013218	September, 1996			ENDOSCOPIC SURGICAL INSTRUMENT
WO/1997/000646	January, 1997			AN ELECTROSURGICAL INSTRUMENT
WO/1997/000647	January, 1997			AN ELECTROSURGICAL INSTRUMENT
WO/1997/010764	March, 1997			VASCULAR TISSUE SEALING PRESSURE CONTROL AND METHOD
WO/1997/024073	July, 1997			AN ELECTROSURGICAL INSTRUMENT AND AN ELECTROSURGICAL ELECTRODE ASSEMBLY
WO/1997/024993	July, 1997			AN ELECTROSURGICAL INSTRUMENT
WO/1998/027880	July, 1998			ELECTROSURGICAL GENERATOR AND SYSTEM FOR UNDERWATER OPERATION
WO/1999/003407	January, 1999			AN ELECTROSURGICAL INSTRUMENT
WO/1999/003408	January, 1999			AN ELECTROSURGICAL INSTRUMENT
WO/1999/003409	January, 1999			AN ELECTROSURGICAL INSTRUMENT
WO/1999/012488	March, 1999			BIPOLAR INSTRUMENT FOR VESSEL FUSION
WO/1999/040857	August, 1999			BONDING OF SOFT BIOLOGICAL TISSUES BY PASSING HIGH FREQUENCY ELECTRIC CURRENT THERETHROUGH
WO/1999/051158	October, 1999			AN ELECTRODE ASSEMBLY FOR AN ELECTROSURGICAL INSTRUMENT
WO/1999/066850	December, 1999			AN ELECTROSURGICAL DEVICE FOR COAGULATING AND FOR MAKING INCISIONS, A METHOD OF SEVERING BLOOD VESSELS AND A METHOD OF COAGULATING AND FOR MAKING INCISIONS IN OR SEVERING TISSUE
WO/2000/024330	May, 2000			OPEN VESSEL SEALING FORCEPS WITH DISPOSABLE ELECTRODES
WO/2000/024331	May, 2000			ENDOSCOPIC BIPOLAR ELECTROSURGICAL FORCEPS
WO/2000/041638	July, 2000			AN ELECTROSURGICAL SYSTEM
WO/2000/053112	September, 2000			DUAL FREQUENCY ELECTROSURGERY SYSTEM
WO/2001/017448	March, 2001			ELECTROSURGICAL COAGULATING AND CUTTING INSTRUMENT
WO/2001/054604	August, 2001			BIPOLAR GRIPPING DEVICE
WO/2002/007627	January, 2002			BIPOLAR ELECTROSURGICAL FORCEPS WITH NON-CONDUCTIVE STOP MEMBERS
WO/2002/080783	October, 2002			VESSEL SEALER AND DIVIDER
WO/2002/080784	October, 2002			ELECTROSURGICAL INSTRUMENT REDUCING THERMAL SPREAD
WO/2002/080785	October, 2002			ELECTROSURGICAL INSTRUMENT REDUCING FLASHOVER
WO/2002/080786	October, 2002			ELECTROSURGICAL INSTRUMENT WHICH REDUCES COLLATERAL DAMAGE TO ADJACENT TISSUE
WO/2002/080793	October, 2002			VESSEL SEALING FORCEPS WITH DISPOSABLE ELECTRODES
WO/2002/080794	October, 2002			VESSEL SEALER AND DIVIDER
WO/2002/080795	October, 2002			VESSEL SEALER AND DIVIDER
WO/2002/080796	October, 2002			VESSEL SEALER AND DIVIDER WITH NON-CONDUCTIVE STOP MEMBERS
WO/2002/080797	October, 2002			VESSEL SEALING INSTRUMENT
WO/2002/080798	October, 2002			MOLDED INSULATING HINGE FOR BIPOLAR INSTRUMENTS
WO/2002/080799	October, 2002			VESSEL SEALER AND DIVIDER
WO/2002/081170	October, 2002			RETRACTABLE OVERMOLDED INSERT RETENTION APPARATUS
WO/2002/098313	December, 2002			BIPOLAR CLAMP
WO/0404/032777	April, 2004
WO/2004/052221	June, 2004			LAPAROSCOPIC BIPOLAR ELECTROSURGICAL INSTRUMENT
WO/2004/073490	September, 2004			VESSEL SEALER AND DIVIDER AND METHOD OF MANUFACTURING SAME
WO/2004/082495	September, 2004			BIPOLAR CONCENTRIC ELECTRODE ASSEMBLY FOR SOFT TISSUE FUSION
WO/2004/098383	November, 2004			ELECTROSURGICAL INSTRUMENT WHICH REDUCES THERMAL DAMAGE TO ADJACENT TISSUE
WO/2004/103156	December, 2004			TISSUE SEALER WITH NON-CONDUCTIVE VARIABLE STOP MEMBERS AND METHOD OF SEALING TISSUE

US 6,090,109, 07/2000, Lands et al. (withdrawn)
US 6,663,629, 12/2003, Buysse et al. (withdrawn)
Sigel et al. “The Mechanism of Blood Vessel Closure by High Frequency Electrocoagulation” Surgery Gynecology & Obstetrics, Oct. 1965 pp. 823-831.
Bergdahl et al. “Studies on Coagulation and the Development of an Automatic Computerized Bipolar Coagulator” J.Neurosurg, vol. 75, Jul. 1991, pp. 148-151.
Kennedy et al. “High-burst-strength, feedback-controlled bipolar vessel sealing” Surgical Endoscopy (1998) 12: 876-878.
Peterson et al. “Comparison of Healing Process Following Ligation with Sutures and Bipolar Vessel Sealing” Surgical Technology International (2001).
Linehan et al. “A Phase I Study of the LigaSure Vessel Sealing System in Hepatic Surgery” Section of HPB Surger, Washington University School of Medicine, St. Louis MO, Presented at AHPBA, Feb. 2001.
Johnson et al. “Evaluation of the LigaSure Vessel Sealing System in Hemorrhoidectormy” American College of Surgeons (ACS) Clinicla Congress Poster (2000).
Sayfan et al. “Sutureless Closed Hemorrhoidectomy: A New Technique” Annals of Surgery vol. 234 No. 1 Jul. 2001 pp. 21-24.
Heniford et al. “Initial Results with an Electrothermal Bipolar Vessel Sealer” Surgical Endoscopy (2000) 15:799-801.
Heniford et al. “Initial Research and Clinical Results with an Electrothermal Bipolar Vessel Sealer” Oct. 1999.
McLellan et al. “Vessel Sealing for Hemostasis During Pelvic Surgery” Int'l Federation of Gynecology and Obstetrics Figo World Congress 2000, Washington, D.C.
Levy et al. “Use of a New Energy-based Vessel Ligation Device During Vaginal Hysterectomy” Int'l Federation of Gynecology and Obstetrics (FIGO) World Congress.
Crawford et al. “Use of the LigaSure Vessel Sealing System in Urologic Cancer Surger” Grand Rounds in Urology 1999 vol. 1 Issue 4 pp. 10-17.
Rothenberg et al. “Use of the LigaSure Vessel Sealing System in Minimally Invasive Surgery in Children” Int'l Pediatric Endosurgery Group (IPEG) 2000.
Palazzo et al. “Randomized clinical trial of Ligasure versus open haemorrhoidectomy” British Journal of Surgery 2002, 89, 154-157.
Int'l Search Report PCT/US01/11218.
Int'l Search Report PCT/US99/24869.
Int'l Search Report PCT/US98/18640.
Int'l Search Report PCT/US98/23950.
PCT/US01/11340, International Search Report.
PCT/US01/11420, International Search Report.
PCT/US02/01890, International Search Report.
PCT/US02/11100, International Search Report.
PCT/US04/03436, International Search Report.
PCT/US04/13273, International Search Report.
PCT/US04/15311, International Search Report.
EP 98944778, International Search Report.
EP 98958575, International Search Report.
EP 04027479, International Search Report.
EP 04027705, International Search Report.
EP 04027314, International Search Report.
“Innovations in Electrosurgery” Sales/Product Literature.
LigaSure Vessel Sealing System, the Seal of Confidence in General, Gynecologic, Urologic, and Laparaoscopic Surgery Sales/Product Literature.
Carbonell et al., “Comparison of theGyrus PlasmaKinetic Sealer and the Valleylab LigaSure Device in the Hemostasis of Small, Medium, and Large-Sized Arteries” Carolinas Laparoscopic and Advanced Surgery Program, Carolinas Medical Center, Charlotte, NC.
“Reducing Needlestick Injuries in the Operating Room” Sales/Product Literature.
Chung et al., “Clinical Experience of Sutureless Closed Hemorrhoidectomy with LigaSure” Diseases of the Colon & Rectum vol. 46, No. 1 Jan. 2003.
Strasberg et al., “Use of a Bipolar Vessel-Sealing Device for Parenchymal Transection During Liver Surgery” Journal of Gastrointestinal Surgery, vol. 6, No. 4, Jul./Aug. 2002 pp. 569-574.
Paul G. Horgan, “A Novel Technique for Parenchymal Division During Hepatectomy” The American Journal of Surgery, vol. 181, No. 3, Apr. 2001 pp. 236-237.
W. Scott Helton, “LigaSure Vessel Sealing System: Revolutionary Hemostasis Product for General Surgery” Sales/Product Literature.
Michael Choti, “Abdominoperineal Resection with the LigaSure Vessel Sealing System and LigaSure Atlas 20 cm Open Instrument” Innovations That Work, Jun. 2003.
Craig Johnson, “Use of the LigaSure Vessel Sealing System in Bloodless Hemorrhoidectomy” Innovations That Work, Mar. 2000.
Muller et al., “Extended Left Hemicolectomy Using the LigaSure Vessel Sealing System” Innovations That Work, Sep. 1999.
Herman et al., “Laparoscopic Intestinal Resection With the LigaSure Vessel Sealing System: A Case Report” Innovations That Work, Feb. 2002.
Carus et al., “Initial Experience With The LigaSure Vessel Sealing System in Abdominal Surgery” Innovations That Work, Jun. 2002.
Levy et al. “Randomized Trial of Suture Versus Electrosurgical Bipolar Vessel Sealing in Vaginal Hysterectomy” Obstetrics & Gynecology, vol. 102, No. 1, Jul. 2003.
Levy et al., “Update on Hysterectomy—New Technologies and Techniques” OBG Management, Feb. 2003.
Barbara Levy, “Use of a New Vessel Ligation Device During Vaginal Hysterectomy” FIGO 2000, Washington, D.C.
McLellan et al. “Vessel Sealing For Hemostasis During Gynecologic Surgery” Sales Product Literature.
Sengupta et al., “Use of a Computer-Controlled Bipolar Diathermy System in Radical Prostatectomies and Other Open Urological Surgery” ANZ Journal of Surgery (2001) 71.9 pp. 538-540.
Olsson et al. “Radical Cystectomy in Females” Current Surgical Techniques in Urology, vol. 14, Issue 3.
E. David Crawford “Use of a Novel Vessel Sealing Technology in Management of the Dorsal Veinous Complex” Sales Product Literature.
Jarrett et al., “Use of the LigaSure Vessel Sealing System for Perl-Hilar Vessels in Laparoscopic Nephrectomy” Sales Product Literature.
E. David Crawford “Evaluation of a New Vessel Sealing Device in Urologic Cancer Surgery” Sales Product Literature.
Joseph Ortenberg “LigaSure System Used in Laparoscopic 1st and 2nd Stage Orchiopaxy” Innovations That Work, Nov. 2002.
Koyle et al., “Laparoscopic Palomo Varicocele Ligation in Children and Adolescents” Pediatric Endosurgery & Innovative Techniques, vol. 6, No. 1, 2002.
Dulemba et al., “Use of a Bipolar Electrothermal Vessel Sealer in Laparoscopically Assisted Vaginal Hysterectomy” Sales Product Literature.
Johnson et al., “Evaluation of a Bipolar electrothermal Vessel Sealing Device in Hemorrhoidectomy” Sales Product Literature.
“Innovations in Electrosurgery” Sales/Product Literature: Dec. 31, 2000.
LigaSure Vessel Sealing System, the Seal of Confidence in General, Gynecologic, Urologic, and Laparaoscopic Surgery Sales/Product Literature: Jan. 2004.
Olsson et al. “Radical Cystectomy in Females” Current Surgical Techniques in Urology, vol. 14, Issue 3, 2001.
Dulemba et al. “Use of a Bipolar Electrothermal Vessel Sealer in Laparoscopically Assisted Vaginal Hysterectomy” Sales Product Literature: Jan. 2004.
Johnson et al. “Evaluation of a Bipolar electrothermal Vessel Sealing Device in Hemorhoidectomy” Sales Product Literature: Jan. 2004.
International Search Report PCT/US01/11224 dated Nov. 13, 2001.
International Search Report EP 98958575.7 dated Sep. 20, 2002.
International Search Report EP 04013772 dated Apr. 1, 2005.
International Search Report EP 05013895 dated Oct. 14, 2005.
International Search Report EP 05017281 dated Nov. 16, 2005.

Compton, Eric

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefits of and priority to U.S. Provisional Patent Application Ser. No. 60/281,924 entitled: “MOLDED INSULATING HINGE FOR BIPOLAR INSTRUMENT” which was filed on Apr. 6, 2001 by Sartor et al., the entire contents of this application are hereby incorporated by reference herein.

What is claimed is:

1. A method of forming a hinge assembly comprising the steps of: providing a pair of first and second elongated shafts each having an end effector attached to a distal end thereof, a handle and a hinge plate, said handle effecting movement of the end effectors relative to one another; mounting said elongated shafts to a die block; introducing an overmold composition into said die block to encapsulate at least a portion of said hinge plates; selectively positioning at least one spacer between said end effectors to maintain a gap distance between said end effectors during the curing step; and curing said overmold composition to form said hinge assembly.

2. A method according to claim 1 wherein said overmold composition of said introducing step includes materials selected from the group consisting of polyamides, nylon, arcylanitride-butane nitro styrene acetyl, polyesters, syndiotactic-polystryrene (SPS), polybutylene terephthalate (PBT), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyphthalamide (PPA), polymide, polyethylene perephthalate (PET), polyamide-imide (PAI), acrylic (PMMA), polystyrene (PS and HIPS), polyether sulfone (PES), aliphatic polyketone, acetal (POM) copolymer, polyurethane (PU and TPU), nylon with polyphenylene-oxide dispersion and acrylonitrile styrene acrylate.

3. A method according to claim 1 wherein said overmold composition of said introducing step includes lubricating materials selected from the group consisting of silicon, molybdenum disulfide and light olefins.

BACKGROUND

1. Technical Field

The present disclosure relates to joints and hinges which connect movable components of an electrosurgical instrument and methods for fabricating hinges for movable components of an electrosurgical instrument. More particularly, the present disclosure relates to an easily customizable hinge made from a plastic overmold composition which connects two end effectors for relative movement therebetween. The present disclosure also relates to a method for fabricating the overmolded hinge.

2. Background of Related Art

Typically, joints and hinges for electrosurgical instruments which connect movable components are formed from an insulating material to prevent shorting between component parts and/or prevent the formation of alternate current paths through the instrument. As such, instrument designers have manufactured electrosurgical instruments which involve complex rotating hinge configurations to isolate, insulate and/or control the electrosurgically active areas of the instrument. For example, traditional metal hinge configurations typically include multiple independent subassemblies which are overmolded with plastic material having high bond strengths. These separately overmolded subassemblies are mechanically integrated and arranged in a series of manufacturing steps that often require tightly controlled and time consuming processes to achieve proper jaw alignment and reliable and consistent gap separation between electrodes. Moreover, additional steps are often undertaken to control other parameters associated with the rotational movement about the hinge, e.g., friction, torque, etc.

Thus, a continuing need exists for a simple and effective insulating hinge that can be readily integrated into the manufacturing process to electrically isolate the movable components of an electrosurgical instrument. Further need exists for the development of a simplified manufacturing process which effectively fabricates an electrosurgical instrument which includes an insulated hinge that isolates and integrates the electrically active components of the instrument and results in the repeated formation of a reliable and easily customizable instrument which meets specific tolerance requirements for proper jaw alignment and gap distances.

SUMMARY

An electrosurgical instrument includes a pair of first and second elongated shafts each having an end effector attached to a distal end thereof and a handle. The handle is movable from a first position wherein the end effectors are disposed in spaced relation relative to one another to a second position wherein the end effectors are closer relative to one another. Each of the elongated shafts includes a hinge plate which mounts atop a pivot assembly for effecting movement of the end effectors relative to one another. The instrument also includes a hinge assembly which is overmolded to encapsulate and secure the hinge plates and the pivot assembly. The hinge assembly is made from an electrically insulating material which insulates the end effectors from one another.

Preferably, the hinge assembly is made from a composition of materials selected from the group consisting of: polyamides, nylon, arcylanitride-butane nitro styrene acetyl, polyesters, syndiotactic-polystryrene (SPS), polybutylene terephthalate (PBT), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyphthalamide (PPA), polymide, polyethylene perephthalate (PET), polyamide-imide (PAI), acrylic (PMMA), polystyrene (PS and HIPS), polyether sulfone (PES), aliphatic polyketone, acetal (POM) copolymer, polyurethane (PU and TPU), nylon with polyphenylene-oxide dispersion and acrylonitrile styrene acrylate. In another embodiment, the hinge assembly is made from a composition of lubricating materials selected from the group consisting of: silicon, molybdenum disulfide and light olefins.

In one embodiment, the pivot assembly includes a pivot pin integrally associated with a first of the hinge plates and a pivot hole formed within a second of the hinge plates. Preferably, the pivot pin is made from an electrically insulating material. In another embodiment, the overmold composition of the hinge assembly is disposed between the pivot pin and the pivot hole to electrically insulate each of the hinge plates from one another.

In yet another embodiment, the hinge assembly includes a retention tab which secures the hinge assembly between the hinge plates. Preferably, the retention tab is formed during the overmold process as the overmold composition leaches through the pivot pin to form a tab on the outer-facing surface of the hinge plate. Once the retention tab cures, the hinge assembly is securely held between the hinge plates. In still yet another embodiment, the hinge assembly includes a stop member for limiting the movement of the end effectors relative to one another.

The present disclosure also relates to a method of forming a hinge assembly and includes the steps of: providing a pair of first and second elongated shafts each having an end effector attached to a distal end thereof, a handle and a hinge plate. The handle is dimensioned to effect movement of the end effectors relative to one another. The method further includes the step of mounting the elongated shafts to a die block, introducing an overmold composition into the die block to encapsulate at least a portion of the hinge plates and curing the overmold composition to form the hinge assembly.

In another embodiment, the method further includes the step of: selectively positioning at least one spacer between the end effectors to maintain a gap distance between the end effectors during the molding and curing step.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the presently disclosed surgical instrument having a molded insulating hinge assembly are described herein with reference to the drawings, wherein:

FIG. 1 is a perspective view of one embodiment of a bipolar forceps having a molded insulating hinge assembly constructed in accordance with the present disclosure;

FIG. 2A is an enlarged, right, side view of an end effector of the bipolar forceps of FIG. 1 prior to overmolding;

FIG. 2B is a bottom view of the end effector of FIG. 2A;

FIG. 2C is a left, side view of the end effector of FIG. 2A;

FIG. 3A is an enlarged, right, side view of a second end effector of the bipolar forceps of FIG. 1 prior to overmolding;

FIG. 3B is a bottom view of the end effector of FIG. 3A;

FIG. 3C is a left, side view of the end effector of FIG. 3A;

FIG. 4 is an exploded, perspective view of the bipolar instrument of FIG. 1; and

FIG. 5 is a perspective view of the embodiment shown in FIG. 1 shown with a spacer disposed between a pair of jaw members to fix a specific gap distance during the overmolding process.

DETAILED DESCRIPTION

Referring now in specific detail to the drawings in which like reference numerals identify similar or identical elements throughout the several views, and initially to FIGS. 1–3C, one particular embodiment of an electrosurgical instrument 10 includes two elongated shafts 30 and 60 each having a distal end effector 32 , 62 and a proximal handle portion 34 and 64 , respectively. Handles 34 and 64 are movable relative to one another about a hinge assembly 20 from a first position wherein the distal end effectors 32 , 62 are positioned in spaced relation relative to one another to a second position in which the distal end effectors 32 , 62 cooperate to grasp tissue therebetween. It is envisioned that handles 34 and 64 may take any design configuration suitable for manipulation or control of the surgical instrument 10 .

Each distal end, e.g., 32 , has a jaw member 36 disposed at the distal end thereof which includes a tissue grasping surface 38 dimensioned to cooperate with the other jaw member, e.g., 66 , and other tissue grasping surface, e.g., 68 , to grasp tissue and other luminal structures upon actuation of the handles 34 and 64 . The jaw members 36 , 66 each also include a hinge plate 35 , 65 , respectively, which cooperate to support opposing sides of the hinge assembly 20 as explained in more detail below. Hinge plate 35 includes a pivot pin 74 which mechanically engages a corresponding pivot hole 61 disposed within hinge plate 65 to form pivot assembly 70 .

Hinge assembly 20 as described herein relates to one particular embodiment for use with a bipolar electrosurgical forceps 10 , however, it is contemplated that the presently disclosed hinge assembly 20 could be dimensioned for use with other electrosurgical instruments including vessel sealing instruments, grasping instruments, ablation instruments, electrosurgical scissors, etc. Moreover, it is also envisioned that the hinge assembly 20 may be configured for use with a broad range of other non-electrical surgical instruments such as pliers, scissors, shears, crimpers and wire cutters.

Preferably, hinge assembly 20 is made from a composition 25 of insulating material such as plastic which is overmolded to encapsulate the hinge plates 35 , 65 during the manufacturing process. As best seen in FIG. 2C, pivot pin 74 includes a reinforcing portion 72 which allows the mold composition 25 to extrude through the pivot pin 74 of hinge plate 35 to an opposite side 63 of hinge plate 65 to form a retention tab 50 . More particularly, after a significant amount of mold composition 25 is extruded around the reinforcing portion 72 of the pivot pin 74 , the retention tab 50 is stamped against the opposite side 63 of hinge plate 65 to secure the hinge plates 35 and 65 in close abutment about the pivot assembly 70 . As can be appreciated in this embodiment of the present disclosure, the mold composition 25 is contiguous with the exterior of the hinge plate 35 through aperture 31 , around reinforcing portion 72 and with the retention tab 50 which securely engages the hinge assembly 20 between the hinge plates 35 , 65 .

As can be appreciated, both the mold composition 25 and the retention tab 50 are formed during the same molding step resulting in the formation of the hinge assembly 20 . It is envisioned that once cured, the retention mechanism 50 forms a structural limit that at least partially controls the alignment of the distal end effectors 32 and 62 as well as the amount of pivotal movement between the jaw members 36 and 66 . Alternatively, the retention tab 50 may be made from the same or a different mold composition 25 and is designed to mechanically engage the pivot pin 74 or the hinge plate 65 to secure the hinge assembly between the hinge plates 35 and 65 .

As best shown in the exploded view of FIG. 4, the formation of the hinge assembly 20 in this manner electrically isolates the two end effectors 32 and 62 and the component parts thereof enabling a user to selectively apply electrosurgical energy through the tissue and between the jaw members 36 and 66 as needed. More particularly, during the overmold process, the plastic cures about the outer periphery 75 of pivot pin 74 which electrically isolates hinge plate 35 from hinge plate 65 . As can be appreciated, the retention tab 50 which, as mentioned above, is also formed of plastic which extrudes through pivot pin 74 to the opposite side 63 of hinge plate 65 , not only retains the two hinge plates 35 and 65 in secure abutment about the pivot assembly 70 but also electrically isolates the hinge plates 35 and 65 from one another.

Because the presently disclosed hinge assembly 20 is preferably formed during a single manufacturing step, it can be easily customized and dimensioned to suit a particular purpose or to achieve a particular result. For example, the alignment of the jaw members 36 and 66 , e.g., jaw angle or jaw offset, may be easily customized depending upon a particular purpose. Moreover, the formation of a gap distance between the jaw members 36 , 66 may be easily customized. For example, the hinge assembly 20 may be molded or formed during the manufacturing process such that the jaw members 36 and 66 maintain a consistent and specific gap distance within the range of about 0.001 inches to about 0.005 inches at closure. The formation of the gap distance is discussed below with particular reference to FIG. 5.

Generally, hinge 20 is formed from an overmold composition containing a joint-forming base resin material and a lubricating component. Hinge-forming materials for use herein can be any commercially available materials known to one skilled in the art for toughness and strength as well as being capable of injection molding. Suitable joint-forming base resin materials include, but are not limited to, polyamides such as nylon, arcylanitride-butane nitro styrene; acetyl, polyesters, etc. Preferably, the overmold composition is made from a plastic or plastic-based material having a Comparative Tracking Index of about 300 volts to about 600 volts for dielectric isolation. For example, the overmold composition 25 may be made from a group of materials selected from a group which includes Nylons, Syndiotactic-polystryrene (SPS), Polybutylene Terephthalate (PBT), Polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), Polyphthalamide (PPA), Polymide, Polyethylene Terephthalate (PET), Polyamide-imide (PAI), Acrylic (PMMA), Polystyrene (PS and HIPS), Polyether Sulfone (PES), Aliphatic Polyketone, Acetal (POM) Copolymer, Polyurethane (PU and TPU), Nylon with Polyphenylene-oxide dispersion and Acrylonitrile Styrene Acrylate. Alternatively, it is envisioned that a non-plastic insulating material, e.g., ceramic, may be used in lieu of or in combination with one or more of the above-identified materials to facilitate the manufacturing process and possibly contribute to more uniform and consistent transfer of electrosurgical energy across the tissue.

Suitable lubricating components for use with the base resin material include a broad range of materials known to compliment the overmold composition to provide mold having a low bonding strength with good surface lubricating qualities. Such lubricating components include, but are not limited to, silicon-like materials, molybdenum disulfide, light olefins, etc. Depending upon the overall composition of the base resin material being used, a lubricating component may not be required.

It is also anticipated that additional materials may be employed in combination with the above materials to achieve suitable levels of toughness and strength in the molded hinge 20 . These additional materials may include, for example, reinforcing agents such as glass fibers, ground glass, or elongated glass fibers. For example, in one particular embodiment, hinge assembly 20 is formed from a commercially available nylon material having about 2.5 wt. % glass fiber reinforcing material and a silicone lubricating component in the range of about 0.75 wt. % to about 10 wt. %. In another embodiment, hinge assembly 20 may be formed from a nylon having glass fiber reinforcing material in the range of about 5 wt. % to about 40 wt. % and silicone in the range of about 2 wt. % to about 8 wt. %.

While silicone or other lubricating agents are typically used in injection molding processes, it has been found that the amount of silicone should be tightly controlled to provide uniform and consistent curing and operating efficiencies. It is envisioned that the silicone component of the overmold composition creates a sustained lubricated surface at the interface between hinge plates 35 and 65 . It has also been found that increasing the level of silicone, e.g., amounts greater than 2 wt. %., in the joint-forming material of hinge assembly 20 , produces an overmold composition having a low bond strength. As can be appreciate, although the overmold composition 25 has a low bond strength to the surrounding metals, i.e., elongated shafts 30 , 60 and hinge plates 35 , 65 , the low bonding strength is offset by a the mechanical advantages of the retention tab 50 and aperture 31 .

As mentioned above, the presently disclosed hinge assembly 20 may be formed during a single manufacturing step and may be easily customized depending upon a particular purpose or to achieve a particular result. For example, parameters such as self lubrication of the hinge assembly 20 , hinge assembly 20 strength, jaw member 36 , 66 alignment, e.g., jaw angle or jaw offset, isolation of the jaw members 36 and 66 during electrosurgical application and the formation of a gap distance between the jaw members 36 ad 66 (or electrodes or probes attached to the jaw members 36 and 66 ) may be easily achieved.

The present application is not limited to the above identified materials, but contemplates a broad range of overmold composition 25 in varying combinations and amounts that provide an overmold composition suitable for the function of hinge assembly 20 . It is envisioned that applications described herein relating to the injection overmolding of thermoplastic polyamides, for example, may be translated into other areas including, but not limited to, other engineering plastic materials, engineering metals and ceramics that may be selectively applied in varying insulative as well as mechanical applications.

The overmold composition 25 of the present disclosure is configured to create a tough and strong hinge assembly 20 by at least partially encapsulating the hinge plates 35 and 65 and the pivot assembly 70 (and the various components thereof). The overmold composition 25 provides suitable strength as a result of its continuity of encapsulation as well as the ability of the overmold composition 25 to form surface features which are specifically dimensioned to improve the strength of the hinge assembly 20 once cured. For example, features within the pivot pin 74 and features within the pivot hole 61 may be provided to increase the overall strength of the instrument and/or hinge assembly 20 , e.g. notches, detents, cavities, overmolded posts, etc. Further, structural strength for the hinge assembly 20 may be gained by coating or filling features defined in the surface of the hinge plates 35 , 65 to augment the mechanical bonding of the plastic mold with the hinge plates 35 , 65 , pivot pins 74 and pivot holes 61 . For example, surface undulations such as lip structures, overhanging shapes, concave shapes, or cantilevered structures having different geometric shapes may be employed to mechanically engages the hinge assembly 20 to the hinge plates 35 .

Preferably, the elongated shafts 30 , 60 are made from a stainless steel material. However, other metal alloys, plastics, ceramics, or composites are also contemplated including combinations of one or more plastics, composites, metals, graphite, carbon-coated plastics and/or any other conductive materials which are well suited for overmolding purposes. Preferably, the elongated shafts 30 and 60 are die-cut, stamped, or micro-machined such that the end effectors 32 and 62 and the hinge plates 35 and 65 from integral parts thereof. As can be appreciated, making these elements integral and utilizing the overmold hinge assembly 20 as presently disclosed herein greatly simplifies the overall manufacturing and assembly processes.

Instrument 10 may also include surface treatments (e.g., nylon powder coatings, chemical treatments, nickel alloy coatings, mechanical finish treatments, shrink tubing, etc.) which facilitate manipulation of the tissue structures, enhance conduction of electrosurgical energy across the jaw members 36 , 66 and/or reduce the likelihood of inconsistencies across the treatment area which may lead to collateral tissue damage, flashover, thermal spread, arcing, etc.

Preferably, the thickness of the hinge assembly 20 can be selectively altered depending upon a particular purpose or for use with a certain instrument. The ultimate thickness and strength of the overmold composition 25 is also related to the viscosity of the overmold composition 25 and the duration and temperature of the curing process. For example, the hinge assembly 20 may include a range of thickness from about 0.020 to about 0.040 inches in thickness. The thickness of the overmold composition 25 also depends on mechanical load bearing and dimensional requirements of a particular application.

As best shown in FIG. 4, the outer periphery 75 of pivot pin 74 provides a basis for the formation of additional molded material around the pivot pin 74 which not only electrically insulates the jaw members 36 and 66 from one another but also reduces the chances of the pivot slipping or rotating when torquing, cross-loading, or shearing forces are applied during the normal use of instrument 10 .

It is envisioned that the hinge assembly may be designed as a more complex mechanism and/or may be designed to encapsulate a more complex pivoting mechanism. For example, it is contemplated that the hinge assembly 20 may include various multiple-link systems such as a two-bar, three-bar or four-bar linkage or may include a two-step hinge. The pivot pin 74 and/or the pivot hole 61 may also be dimensioned in a variety of different shapes and sizes depending upon a particular purpose or to achieve a particular result, e.g., cam and cam-follower, arcuate, elliptical, etc. It is also envisioned that the hinge assembly 20 may include one or more stop members 19 which limit the overall distance that the jaw members 36 , 66 may pivot in either the open or closed positions. The stops 19 may be configured in steps or as a cantilevered feature to define more than one gap distance between jaw members 36 and 66 .

In one embodiment, retention tab 50 may be configured to mechanically engage a portion of the hinge plate 65 and/or pivot pin 74 which is contemplated to serve two purposes: 1) to mechanically retain the retention tab 50 against the hinge plate 65 and further secure the instrument 10 as assembled; and 2) to bias the pivot assembly 70 to a predetermined open, closed, or intermediary position. For example, the outer-facing surface 63 of hinge plate 65 may be provided with slots or grooves (not shown) which mechanically engage the retention tab 50 .

With respect the to particular surgical instrument of FIGS. 1–4, i.e., bipolar forceps 10 , first and second conductive wires 41 and 45 are each electrically coupled to a respective distal end effector 32 and 62 at one end thereof and ultimately connected to an electrosurgical generator (not shown) at the opposite end thereof. The first electrical conductor 41 (see FIG. 2A) connects the first jaw member 36 to a first electrical potential and the second electrical conductor 45 (see FIG. 3A) connects the second jaw member 66 to a second electrical potential. Preferably, the first and second electrical conductors 41 and 45 are disposed within longitudinally-oriented channels defined within elongated shafts 30 and 60 , respectively. The channels are preferably oriented and dimensioned to facilitate mechanical engagement of the electrical conductors 41 and 45 with the respective jaw members 36 and 66 in such a manner to allow free, pivotable movement of the jaw members 36 and 66 relative to one another. Preferably, the cable leads are attached to the electrically conductive jaw members 36 and 66 by a crimp-like electrical connection (not shown). As mentioned above, the hinge assembly 20 includes at least one stop 19 which abuts against elongated shafts 30 , 60 to prevent over-rotation of the jaw members 36 and 66 to avoid straining the electrical leads.

Preferably, hinge assembly 20 is manufactured in a single injection molding or manufacturing process step in which elongated shafts 30 and 60 are mounted atop a die block within an injection molding machine. The overmold composition 25 of the hinge assembly 20 is then injected between the jaw members 36 and 66 to encapsulate the hinge plates 35 and 65 and the pivot assembly 70 . As mentioned above, the hinge assembly 20 is strengthened by the continuity of the plastic overmold composition 25 which extrudes through the pivot pin 74 and pivot hole 61 to form the retention tab 50 . Thus, in one particular embodiment, the hinge assembly 20 is completely formed by overmold composition flowing around and through the various components parts of the hinge assembly 20 and the pivot assembly 70 . As mentioned above, the retention tab may be a separate component made from the same or a similar composition which is dimensioned to mechanically engage the pivot pin 74 or the outer-facing surface 63 of the hinge plate 65 .

As mentioned briefly above and as shown in FIG. 5, a spacer 100 may be positioned between jaw members 36 and 66 prior to the overmolding process. The spacer 100 sets a fixed gap distance “G” between jaw members 36 and 66 at closure (i.e., when the jaw members 36 and 66 are disposed in the closed or tissue grasping position) by limiting the formation of the stop 19 during the overmolding process. As can be appreciated, different and/or customized gap distances “G” between the jaw members 36 and 66 can be easily formed depending upon a particular purpose or to achieve a particular result.

The presently disclosed overmolding process also enables the manufacturer to customize the precise alignment of the jaw members 36 and 66 relative to one another. Thus, in applications in which the alignment of jaw members 36 and 66 is critical, such as for shearing, cutting and sealing, the accuracy, alignment and configuration of the hinge assembly 20 , pivot assembly 70 and jaw members 36 and 66 can be easily customized. Further, the presently disclosed process also provides a repeatable and reliable alignment tool for mass manufacturing of surgical instruments according to specific tolerances.

From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the present disclosure. For example, it is contemplated that hinge assembly 20 can be configured to join a plurality of different components or subassemblies in the assembly depending upon a particular purpose. Moreover, the outer periphery 75 of pivot pin 74 could also include features such as a series of undulations or knurling, or a series of radially aligned cavities having features within those cavities that strengthen the mechanical interface of the overmold composition to the pivoting assembly 70 .

In one embodiment, the instrument includes a conductive strip (not shown) disposed through one shaft, e.g., shaft 30 . Electrosurgical wires or cables (not shown) from an electrosurgical generator (not shown) connect the two electrical potentials to the conductive strip. The opposite end of the conductive strip includes one electrical connection to end effector 32 and a second electrical connection to pivot assembly 70 which provides electrical continuity to the opposite end effector 62 . More particularly, the second electrical connection of the conductive strip makes contact across the moving junction of the pivot assembly. It is not necessary that the conductive strip wrap around the pivot pin 74 between the instrument halves because during the molding process the conductive strip is forced into intimate contact with the opposite end effector 62 , i.e, the flow of the uncured hinge material positions the conductive strip into contact with end effector 62 .

As a result thereof, secondary washers or force loading devices are not required to initiate contact between the conductive strip and the opposite end effector 62 . The conductive strip my also include a series of wave-like folds, e.g., accordion folds, which give the conductive strip a spring-like quality and which fosters contact with the opposite end effector 62 during and after curing. As can be appreciated, this arrangement assures that a moving or sliding contact is maintained between the conductive strip and the end effector 62 during movement, i.e., pivoting, of the end effectors relative to one another.

While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.